Lenticular pattern forming roll and method for making the roll

Abstract

A lenticular pattern forming roll, used for forming a lenticular screen, includes a chill roll and a lenticular sleeve positioned on the chill roll. The lenticular sleeve has a lenticular pattern formed on an outer surface for forming a corresponding lenticular pattern in a plastic sheet. The sleeve may be readily manufactured and transported to a desired location to be installed on the chill roll. The lenticular pattern forming roll may be readily used in combination with an extruder for extruding a hot plastic sheet to form the lenticular screen. The sleeve may also be removed from the chill roll and transported for resurfacing and without requiring transporting of the chill roll. The lenticular sleeve may preferably comprise a nickel-phosphorous composition defining at least a radially outermost portion of the sleeve in which the lenticular pattern is formed. More particularly, the nickel-phosphorous composition is preferably an amorphous nickel-phosphorous composition comprising nickel in a range of about 75 to 86 percent by weight, and phosphorous in a range of about 14 to 25 percent by weight. The nickel-phosphorous composition may be formed by electrodepositing or electroless depositing. The lenticular sleeve may be slit and flattened to define a flat lenticular body for molding a lenticular screen.

That which is claimed is: 
     
       1. A lenticular pattern forming roll for forming a lenticular screen, said lenticular pattern forming roll comprising: a chill roll having a generally cylindrical shape and for accepting a cooling fluid therethrough; and   a lenticular sleeve positioned on said chill roll, said lenticular sleeve comprising a nickel-phosphorous composition and having a lenticular pattern formed on an outer surface thereof for forming a corresponding lenticular pattern in a plastic sheet passed adjacent thereto.   
     
     
       2. A lenticular pattern forming roll according to claim 1 wherein said nickel-phosphorous composition defines at least a radially outermost portion in which said lenticular pattern is formed. 
     
     
       3. A lenticular pattern forming roll according to claim 1 wherein said nickel-phosphorous composition is an amorphous nickel-phosphorous composition. 
     
     
       4. A lenticular pattern forming roll according to claim 1 wherein said nickel-phosphorous composition comprises at least about 75 percent nickel by weight. 
     
     
       5. A lenticular pattern forming roll according to claim 1 wherein said nickel-phosphorous composition comprises less than about 86 percent nickel by weight. 
     
     
       6. A lenticular pattern forming roll according to claim 1 wherein said nickel-phosphorous composition comprises at least about 14 percent phosphorous by weight. 
     
     
       7. A lenticular pattern forming roll according to claim 1 wherein said nickel-phosphorous composition comprises less than about 25 percent phosphorous by weight. 
     
     
       8. A lenticular pattern forming roll according to claim 1 wherein said nickel-phosphorous composition is an electrodeposited nickel-phosphorous composition. 
     
     
       9. A lenticular pattern forming roll according to claim 1 wherein said nickel-phosphorous composition is an electroless deposited nickel-phosphorous composition. 
     
     
       10. A lenticular pattern forming roll according to claim 1 wherein said nickel-phosphorous composition has a Rockwell C hardness of at least about 45. 
     
     
       11. A lenticular pattern forming roll according to claim 1 wherein an interior surface of said lenticular sleeve has a predetermined diameter relative to an outer diameter of an adjacent exterior surface of said chill roll to frictionally engage same. 
     
     
       12. A lenticular pattern forming roll according to claim 1 wherein an interior surface of said lenticular sleeve has a predetermined surface roughness to frictionally engage an adjacent exterior surface of said chill roll. 
     
     
       13. A lenticular pattern forming roll according to claim 12 wherein said predetermined surface roughness of said lenticular sleeve has a coefficient of friction of at least about 0.1. 
     
     
       14. A lenticular pattern forming roll according to claim 1 further comprising an adhesive layer between an interior surface of said lenticular sleeve and an adjacent surface of said chill roll. 
     
     
       15. A lenticular pattern forming roll according to claim 14 wherein said adhesive layer comprises at least one of a meltable adhesive and a meltable solder. 
     
     
       16. A lenticular pattern forming roll for forming a lenticular screen, said lenticular pattern forming roll comprising: a chill roll having a generally cylindrical shape and for accepting a cooling fluid therethrough; and   a lenticular sleeve positioned on said chill roll in frictional engagement therewith, said lenticular sleeve having a lenticular pattern formed on an outer surface thereof for forming a corresponding lenticular pattern in a plastic sheet passed adjacent thereto, said lenticular sleeve comprising a nickel-phosphorous composition defining at least a radially outermost portion of said sleeve in which said lenticular pattern is formed.   
     
     
       17. A lenticular pattern forming roll according to claim 16 wherein said nickel-phosphorous composition is an amorphous nickel-phosphorous composition. 
     
     
       18. A lenticular pattern forming roll according to claim 16 wherein said nickel-phosphorous composition comprises nickel in a range of about 75 to 86 percent by weight, and phosphorous in a range of about 14 to 25 percent by weight. 
     
     
       19. A lenticular pattern forming roll according to claim 16 wherein said nickel-phosphorous composition is an electrodeposited nickel-phosphorous composition. 
     
     
       20. A lenticular pattern forming roll according to claim 16 wherein said nickel-phosphorous composition is an electroless deposited nickel-phosphorous composition. 
     
     
       21. A lenticular pattern forming roll according to claim 16 wherein said nickel-phosphorous composition has a Rockwell C hardness of at least about 45. 
     
     
       22. A lenticular pattern forming roll according to claim 16 wherein an interior surface of said lenticular sleeve has a predetermined diameter relative to an outer diameter of an adjacent exterior surface of said chill roll to frictionally engage same. 
     
     
       23. A lenticular pattern forming roll according to claim 14 wherein an interior surface of said lenticular sleeve has a predetermined surface roughness to frictionally engage an adjacent exterior surface of said chill roll. 
     
     
       24. A lenticular pattern forming roll according to claim 23 wherein said predetermined surface roughness of said lenticular sleeve has a coefficient of friction of at least about 0.1. 
     
     
       25. A lenticular pattern forming roll according to claim 16 further comprising an adhesive layer between an interior surface of said lenticular sleeve and an adjacent surface of said chill roll. 
     
     
       26. A lenticular pattern forming roll according to claim 25 wherein said adhesive layer comprises at least one of a meltable adhesive and a meltable solder. 
     
     
       27. A lenticular sleeve for positioning over a chill roll having a generally cylindrical shape for accepting a cooling fluid therethrough, said lenticular sleeve comprising: a tubular body comprising a nickel-phosphorous composition and having a lenticular pattern formed on an outer surface thereof for forming a corresponding lenticular pattern in a plastic sheet passed adjacent thereto.   
     
     
       28. A lenticular sleeve according to claim 27 wherein said nickel-phosphorous composition defines at least a radially outermost portion in which said lenticular pattern is formed. 
     
     
       29. A lenticular sleeve according to claim 27 wherein said nickel-phosphorous composition is an amorphous nickel-phosphorous composition comprising nickel in a range of about 75 to 86 percent by weight, and phosphorous in a range of about 14 to 25 percent by weight. 
     
     
       30. A lenticular sleeve according to claim 27 wherein said nickel-phosphorous composition has a Rockwell C hardness of at least about 45. 
     
     
       31. An apparatus for making a lenticular screen, said apparatus comprising: an extruder for extruding a hot plastic sheet; and   a lenticular pattern forming roll downstream from said extruder, said lenticular pattern forming roll comprising: a chill roll having a generally cylindrical shape and for accepting a cooling fluid therethrough, and   a lenticular sleeve positioned on said chill roll , said lenticular sleeve comprising a nickel-phosphorous composition and having a lenticular pattern formed on an outer surface thereof for forming a corresponding lenticular pattern in the plastic sheet passed adjacent thereto.     
     
     
       32. An apparatus according to claim 31 wherein said lenticular sleeve is frictionally engaged on said chill roll. 
     
     
       33. An apparatus according to claim 31 wherein said lenticular sleeve is adhesively secured on said chill roll. 
     
     
       34. An apparatus according to claim 31 wherein said nickel-phosphorous composition is an amorphous nickel-phosphorous composition comprising nickel in a range of about 75 to 86 percent by weight, and phosphorous in a range of about 14 to 25 percent by weight. 
     
     
       35. An apparatus according to claim 31 wherein said nickel-phosphorous composition has a Rockwell C hardness of at least about 45. 
     
     
       36. A method for making a lenticular pattern forming roll for forming a lenticular screen, the method comprising the steps of: providing a chill roll having a generally cylindrical shape for accepting a cooling fluid therethrough;   providing a lenticular sleeve comprising a nickel-phosphorous composition and having a lenticular pattern on an outer surface thereof for forming a corresponding lenticular pattern in a plastic sheet passed adjacent thereto; and   positioning the lenticular sleeve on the chill roll to define the lenticular pattern forming roll.   
     
     
       37. A method according to claim 36 wherein the step of providing the lenticular sleeve comprises the steps of: forming a metal layer on a mandrel;   cutting the lenticular pattern in an outer surface of the metal layer while on the mandrel to form the lenticular sleeve; and   freeing the lenticular sleeve from the mandrel.   
     
     
       38. A method according to claim 37 wherein the steps of forming, cutting, and freeing are performed remote from the chill roll; and further comprising the step of transporting the lenticular sleeve from the mandrel to the chill roll. 
     
     
       39. A method according to claim 37 wherein the step of freeing the lenticular sleeve from the mandrel comprises expanding the lenticular sleeve by injecting fluid between the mandrel and the lenticular sleeve. 
     
     
       40. A method according to claim 37 wherein the lenticular sleeve and the mandrel have different coefficients of thermal expansion; and wherein the step of freeing the lenticular sleeve from the mandrel comprises freeing same based upon the different coefficients of thermal expansion. 
     
     
       41. A method according to claim 37 wherein the step of forming the metal layer comprises forming the nickel-phosphorous composition. 
     
     
       42. A method according to claim 41 wherein the step of forming the nickel-phosphorous composition comprises forming an amorphous nickel-phosphorous composition comprising nickel in a range of about 75 to 86 percent by weight, and phosphorous in a range of about 14 to 25 percent by weight. 
     
     
       43. A method according to claim 41 wherein the step of forming the nickel-phosphorous composition comprises electrodepositing the nickel-phosphorous composition. 
     
     
       44. A method according to claim 41 wherein the step of forming the nickel-phosphorous composition comprises electrolessly depositing the nickel-phosphorous composition. 
     
     
       45. A method according to claim 41 further comprising the step of hardening the nickel-phosphorous composition to have a Rockwell C hardness of at least about 45. 
     
     
       46. A method according to claim 36 wherein the step of positioning the lenticular sleeve on the chill roll comprises frictionally engaging the lenticular sleeve onto the chill roll. 
     
     
       47. A method according to claim 36 further comprising the step of forming an interior surface of the lenticular sleeve to have a predetermined surface roughness to frictionally engage an adjacent exterior surface of the chill roll. 
     
     
       48. A method according to claim 36 wherein the step of positioning the lenticular sleeve on the chill roll comprises expanding the lenticular sleeve by injecting a fluid between the chill roll and the lenticular sleeve. 
     
     
       49. A method according to claim 36 wherein the lenticular sleeve and the chill roll have different coefficients of thermal expansion; and wherein the step of positioning the lenticular sleeve on the chill roll comprises positioning same based upon the different coefficients of thermal expansion. 
     
     
       50. A method according to claim 36 wherein the step of positioning the lenticular sleeve on the chill roll comprises securing the lenticular sleeve to the chill roll using a meltable adhesive. 
     
     
       51. A method for making a lenticular sleeve to be used in an apparatus for forming a lenticular screen, the apparatus including a chill roll having a generally cylindrical shape and for accepting a cooling fluid therethrough, the method comprising the steps of: forming a metal layer comprising a nickel-phosphorous composition on a mandrel;   cutting a lenticular pattern in an outer surface of the metal layer while on the mandrel to form the lenticular sleeve; and   freeing the lenticular sleeve from the mandrel.   
     
     
       52. A method according to claim 51 wherein the steps of forming, cutting, and freeing are performed remote from the chill roll. 
     
     
       53. A method according to claim 51 wherein the step of freeing the lenticular sleeve from the mandrel comprises expanding the lenticular sleeve by injecting fluid between the mandrel and the lenticular sleeve. 
     
     
       54. A method according to claim 51 wherein the lenticular sleeve and the mandrel have different coefficients of thermal expansion; and wherein the step of freeing the lenticular sleeve from the mandrel comprises freeing same based upon the different coefficients of thermal expansion. 
     
     
       55. A method according to claim 51 wherein the step of forming the metal layer comprises forming the nickel-phosphorous composition. 
     
     
       56. A method according to claim 55 wherein the step of forming the nickel-phosphorous composition comprises forming an amorphous nickel-phosphorous composition comprising nickel in a range of about 75 to 86 percent by weight, and phosphorous in a range of about 14 to 25 percent by weight. 
     
     
       57. A method according to claim 55 wherein the step of forming the nickel-phosphorous composition comprises electrodepositing the nickel-phosphorous composition. 
     
     
       58. A method according to claim 55 wherein the step of forming the nickel-phosphorous composition comprises electrolessly depositing the nickel-phosphorous composition. 
     
     
       59. A method according to claim 55 further comprising the step of hardening the nickel-phosphorous composition to have a Rockwell C hardness of at least about 45. 
     
     
       60. A method for making a body having a lenticular pattern thereon to be used for forming a lenticular screen, the method comprising the steps of: forming a metal layer comprising a nickel-phosphorous composition on a mandrel;   cutting a lenticular pattern in an outer surface of the metal layer while on the mandrel to form a lenticular sleeve; and   freeing the lenticular sleeve from the mandrel.   
     
     
       61. A method according to claim 60 further comprising the steps of: slitting the lenticular sleeve; and   flattening the slit lenticular sleeve to define a flat lenticular form.   
     
     
       62. A method according to claim 60 wherein the step of freeing the lenticular sleeve from the mandrel comprises expanding the lenticular sleeve by injecting fluid between the mandrel and the lenticular sleeve. 
     
     
       63. A method according to claim 60 wherein the lenticular sleeve and the mandrel have different coefficients of thermal expansion; and wherein the step of freeing the lenticular sleeve from the mandrel comprises freeing same based upon the different coefficients of thermal expansion. 
     
     
       64. A method according to claim 60 wherein the step of forming the metal layer comprises forming the nickel-phosphorous composition. 
     
     
       65. A method according to claim 64 wherein the step of forming the nickel-phosphorous composition comprises forming an amorphous nickel-phosphorous composition comprising nickel in a range of about 75 to 86 percent by weight, and phosphorous in a range of about 14 to 25 percent by weight. 
     
     
       66. A method according to claim 64 wherein the step of forming the nickel-phosphorous composition comprises electrodepositing the nickel-phosphorous composition. 
     
     
       67. A method according to claim 64 wherein the step of forming the nickel-phosphorous composition comprises electrolessly depositing the nickel-phosphorous composition. 
     
     
       68. A method according to claim 64 further comprising the step of hardening the nickel-phosphorous composition to have a Rockwell C hardness of at least about 45.